Apparatus and Method for Multilayer Shower Base

ABSTRACT

Methods and apparatus for multilevel shower bases are defined. The multilevel shower base structure may comprise an impregnable base layer with interface to drain and a super-layer structure base that may drain water through its body to the underlying base layer. Various design and function aspects may be enabled by the structure of the multilevel shower base. In some embodiments, one or more sensors, including temperature sensors, occupancy sensors, and/or light sensors may be incorporated.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This Application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/473,173, filed on Mar. 17, 2017, and titled “APPARATUS AND METHOD FOR MULTILAYER SHOWER BASE” the entire contents which are incorporated herein by this reference.

FIELD OF THE INVENTION

The present invention relates to apparatus and methods for shower base structure. More specifically, the present invention relates to multilevel shower bases wherein a non-permeable base layer may interface with a drain structure while supporting overlaying layers.

BACKGROUND

Standard shower bases may be formed of impermeable materials that interface with drain structures. The drain structures may connect to installed location plumbing for drainage. The standard impermeable materials may limit the ability to incorporate design structures and functional aspects like draining features. The resulting limitations may impact cost effective incorporation of novel features for a shower environment.

It may be desirable to form shower bases which allow for standard interfacing, water impermeability, safety and conformance to building code while simultaneously allowing for customized and flexible design aspects to be incorporated into an installed shower base.

SUMMARY

Accordingly, the present invention provides apparatus and methods for forming a multilevel shower base with a standard impenetrable and impermeable base layer that interfaces with drain connections in an installed bath/shower location floor as well as a super-layer that is supported in a fixed position above the base layer and incorporates design and other functional aspects into the shower environment.

In accordance with some aspects of the disclosure, a multilevel shower base including an impregnable base, a flange used at least partially to support a super-layer structure base on top of the impregnable base, and a drain connection positioned on the impregnable base and interfacing with the existing drain plumbing is disclosed. In some embodiments, the impregnable base layer is at least partially slopped and has an array of disparate supporting structures to account for the at least partially slopped portion as to enable post-manufacturing sizing and interfacing with an existing drain plumbing. The super-layer base may be permeable and include a series of openings to enable the penetration of steam or water.

In accordance with additional aspects, the multilevel shower base may also include one or more sensors configured to send a signal to effectuate a function of one or both the multilevel shower base and a shower space. The one or more sensors may include one or both of a pressure sensor and an occupancy sensor, for example. Other sensors may include one or more of a temperature sensor, a light sensor, and a humidity sensor. One or more sensors may be configured to transmit a signal relating to a measurement to a smart device using a local area network.

In accordance with yet additional aspects, directional steam elements and/or light fixture elements may also be included. The super-layer structure base may have a top layer comprising one or more of stone, marbles, pebbles, or sand.

There has thus been outlines, rather broadly, certain aspects of the disclosure in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional aspects of the invention that will be described below and which will form the subject matter of the claims appended hereto.

In this respect, before explaining at least one aspect of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of aspects in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and show not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as basis for the designing of other method and systems for carrying out the several purposes of the invention. It is important, therefore, that the claims be regarded as included such equivalent constructions insofar as they do not depart from the spirit and scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the disclosure and, together with the description, explain the principles of the disclosure.

FIG. 1 illustrates an exemplary multilevel shower base structure.

FIG. 2 illustrates an exemplary square impregnable base design for a multilevel shower base.

FIG. 3 illustrates an exemplary rectangular impregnable base design with a one ended drain design and sloping structure of a multilevel shower base.

FIG. 4 illustrates an exemplary multilevel shower base with stone features on the super-layer structure base.

FIG. 5 illustrates an exemplary multilevel shower base with marble shaped raised topography on the super-layer structure base.

FIG. 6 illustrates an exemplary multilevel shower base with a pebble type surface on the super-layer structure base.

FIG. 7 illustrates an exemplary multilevel shower base with a sand typed surface on the super-layer structure base.

FIG. 8 illustrates an exemplary multilevel shower base with steam or other vapors or mixtures of vapors emanating from the floor.

FIG. 9 illustrates an exemplary multilevel shower base with steam, other vapor, or mixtures of vapors emanating from between tiles on the side of the multilevel shower base.

DETAILED DESCRIPTION

In the following detailed description of the various embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration various embodiments in which aspects of the disclosure may be practiced. It is to be understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope and spirit of the present disclosure.

Definitions

As used herein “impregnable base” refers to a non-permeable base layer that includes slopping characteristics to help direct water towards a drain opening. In accordance with some aspects, the impregnable base includes an array of supporting structures that enable the sizing/cutting of the impregnable base to fit an existing shower floor space and to interface with the existing drain plumbing structures without affecting the slopping characteristics of the impregnable base.

As used herein “multilayer shower base” or “multilevel shower base” refers to a shower base that includes an impregnable base and a super-layer structure base.

As used herein “super-layer structure base” refers to a customizable permeable layer that can be positioned onto an impregnable base.

As used herein “shower base sensor” refers to one or more sensors that may be located on, or to effectuate, a function/feature of the multilayer shower base. In some embodiments, the sensor may include, for example, an occupancy sensor, a pressure sensor, temperature sensor, humidity sensor, light sensor and the such.

With reference to the drawings, the apparatus and method for multilayer shower base will now be described.

Referring to FIG. 1, a cross section of an exemplary multilevel shower base 100 is illustrated. A standard impregnable base 105 may be molded or otherwise formed with sealed drain connections. The standard impregnable base 105 may be formulated in standard shapes and sizes. The standard impregnable base 105 may be cut to a custom size in a manufacturing, warehouse or job site location. Above the standard impregnable base may be a flange 110 that is used to attach and seal over layers to the standard impregnable base 105. The over layers may include a flange connected tiling support feature 130. The flange may also have features to attach and support a super-layer structure base 120. This super-layer structure base 120 may support various customizable design shapes, surface features, and other functional aspects. The super-layer structure base 120 may have penetrations 125 that allow for water to flow through it towards the drain. In other examples, the material of the super-layer structure base 120 may be porous and allow water to flow through without noticeable penetrations. In some further examples, the penetrations may be gaps rather than holes that are formed between design features such as rocks and the like.

The flange connected tiling support feature 130 may have or allow the attachment of tiles 140. In the interstices between adjacent tiles such as vertical gaps 141 and horizontal gaps 142 there may be connections to tubes or other material cavities that may allow steam, water, or other aspects to be released into the shower. In some examples, such function as aroma release may be functionalized between the tiles. In some other examples, the holes in the super-layer structure base 120 may also be used to allow for steam or aroma to be released.

The standard impregnable base 105 may be molded to have a drain connection 115 connected to it. Large standard impregnable bases may be cut to size to fit a location and to adjust the actual location of the drain connection as necessary. The use of a standard impregnable base may provide an economic shower base aspect while allowing for the incorporation of novel features to the shower environment which may not be possible with a standard one level shower base design with its associated drain connections. Since the base may have a taper to it to facilitate water flow, there may be the necessity to provide some level of shimming to a flange when the base is cut to a customized size and shape. As well, in some examples, there may be supporting pieces or structures that are affixed, joined, glued or otherwise attached to the standard impregnable base 105 to provide physical support of the super-layer structure base 120 as well as adjustable leveling aspects. In some examples a standard impregnable base may have associated attachment features such as tapped holes at a grid across the base to allow for the attachment and adjustment of support pieces to the base and super-layer structure base 120. As shown, a super-layer structure base 120 may be the second of a multilevel shower base system 100. In some examples there may even be additional levels incorporated into the shower base for various functions such as steam outlet. In some examples, steam may have both an aesthetic function and a cleansing function for the multilevel shower base.

There may be various electrical controllers and programable devices that may be incorporated to control the features enabled by a multilevel shower base including but not limited to the flow of steam, control of temperature of the base and the like. A controller may include memory and various input and output devices. The controller may include wireless and wired communication function that may interface with a user through a display panel, voice active commands or the like. Programming of the various function and diagnostic capabilities may be performed through wired or wireless communication which may interface to standard mobile devices such as mobile phones, tablets and the like. Sensors of various types including temperature and humidity as non-limiting examples may be incorporated. Other sensors may also include occupancy sensors and/or pressure sensors as to detect when a person enters the shower/bath space and to transmit a signal as to activate a function and/or provide a measurement. Functions of the sensors may include, for example, an enclosure dimming or change in translucent light properties, or illuminating properties of a light fixture, such as, an emergency light. Measurements may include, for example, temperature measurements and/or the weight of the individual on the shower base. Measurements may be transmitted to a home smart device using a wire connection or a wireless connection, including, for example, a local area network.

In some examples, various types of lighting may be incorporated into the multilevel shower base for various effects. The light may be caused to emanate from the various penetrations of the super-layer structure base, or from between the tiles on the flanged portions above the base. In some examples, light emitting diode may be attached to the structure, in other examples, they may be embedded or encapsulated into portions of the super-layer structure base. In other examples, optical fiber may be used to guide light to desired locations on the superstructure or on attached flanged layers. In some cases, the optical fiber may allow for light to be emanated from locations without penetration.

In some examples, the super-layer structure base may be attached to the impregnable base in manners that allow for relatively easy access between the layers for maintenance and upgrades of various types. Fasteners or molded attachment devices such as clips may be useful to allow for a removable functionality.

Referring to FIG. 2, a standard impregnable base 200 of a square type shape is illustrated with a central drain and sloped sides to guide water to a drain. The level of slope may vary significantly for different designs. As mentioned, the exact shape of the base may be varied at the manufacturing plan, at a distributor or on site in various examples.

Referring to FIG. 3, a standard impregnable base 300, of a rectangular type shape is illustrated with an off center drain and a sloped shape along the long axis of the rectangle is illustrated. Such a base may have similar features for interfacing with flanges to incorporate the multilevel shower base structure.

Referring to FIG. 4 a super-layer structure base 400 is illustrated with design features such as stone or slate which may be real or molded. In some examples where the stones are densely placed water may be able to drain in the gaps between the stone features in a natural manner.

Referring to FIG. 5, a super-layer structure base 500 is illustrated with design feature such as round bumps or marble shaped bumps on the surface. Larger density of such features than is illustrated is within the scope of the inventive art herein.

Referring to FIG. 6, a super-layer structure base 600 is illustrated with a design feature such as pebbles or small stones on the surface.

Referring to FIG. 7, a super-layer structure base 700 is illustrated with a sand based surface.

Referring to FIG. 8, a multilevel shower base 800 is illustrated with steam or other vapors emanating. The release of the vapors may include such aspects as aroma therapy, or just aroma. The release of the vapors may be combined with light function. In some examples, the light may be modulated to elucidate various effects such as fire, lava, or other light-based effects.

Referring to FIG. 9, a multilevel shower base 900 is illustrated with steam emanating from the sides of a super-layer structure base with tiling. The tiling is shown in a regular pattern but that is for illustration only and various types, shapes and patterns of tiling may be made. As well, added function such as lighting may be incorporated to the flanged upper levels and may be coordinated with the release of vapors, steam or mixtures of vapors as mentioned previously.

Other aspects of a multilevel shower base can be incorporated. In some examples, the structure may be a shower base or any wet area floor without any type of visible drain. In some examples the multilevel shower base is constructed with two layers, in other examples there may be more than two layers. The bottom layer also called the standard impregnable base may be a functional part with integrated flanges for tiling and a tray for the top layer or super-layer structure base to sit. The initial impregnable base may be made in an oversized rectangular block formed from any substrate in which a single mold produces an impermeable substrate. The impregnable base may then be easily cut to fit any size.

The super-layer structure base or top layer may include a variety of materials and objects from glass marbles to sand, Tetris shaped block tiling, teak, laser cut steel, plastic, and the like. In some examples, the water may seep through cracks in top layer or in formed penetrations. The water that flows through may then be channeled to a STD no caulk drain.

There may be various effects that may be achieved as a novel steam shower where steam rises up from a porous floor. This may be similar to an effect of a natural hot spring.

Light effects may be possible as mentioned. In some examples light may emanate out from cracks as well as from opaque top layer materials such as materials utilized in glass rock fire pits.

In some examples, water drains down through cracks or penetrations in a flat non-sloped top layer or super-layer structure base. There may be steam vapor or led light which may rise or emanate from the cracks or penetrations where water is draining. The bottom impregnable substrate layer may be manufactured to be of a standard oversized size and cut down. Separate arrays of support structures below the sloped impregnable substrate layer allow the cutting down of the oversized substrate layer without affecting the slopping and enabling interfacing of the impregnable substrate layer's drain with that of the existing plumbing.

In some examples a standard size may be employed for the impregnable base layer. There may be economic advantages of a standard base that incorporates required aspects for drainage. Accordingly, the top layer could be of a variety of complexity and material cost options and for different types of application environments such as retail, designer collaborations, hospitality, or showrooms.

While embodiments of the present disclosure are described herein by way of example using several illustrative drawings, those skilled in the art will recognize the present disclosure is not limited to the embodiments or drawings described. It should be understood the drawings and the detailed description thereto are not intended to limit the present disclosure to the form disclosed, but to the contrary, the present disclosure is to cover all modification, equivalents and alternatives falling within the spirit and scope of embodiments of the present disclosure as defined by the appended claims.

The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures.

The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted the terms “comprising”, “including”, and “having” can be used interchangeably.

Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in combination in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in a sequential order, or that all illustrated operations be performed, to achieve desirable results. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.

In certain implementations, multitasking and parallel processing may be advantageous. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the claimed disclosure. 

What is claimed is:
 1. A multilevel shower base comprising: an impregnable base, wherein the impregnable base layer is at least partially slopped and has an array of disparate supporting structures to account for the at least partially slopped portion as to enable post-manufacturing sizing and interfacing with an existing drain plumbing; a flange used at least partially to support a super-layer structure base on top of the impregnable base; and a drain connection positioned on the impregnable base and interfacing with the existing drain plumbing.
 2. The multilevel shower base of claim 1, wherein the super-layer base is permeable and includes a series of openings to enable the penetration of steam or water.
 3. The multilevel shower base of claim 1, additionally comprising: one or more sensors configured to send a signal to effectuate a function of one or both the multilevel shower base and a shower space.
 4. The multilevel shower base of claim 3, wherein the one or more sensors include one or both of a pressure sensor and an occupancy sensor.
 5. The multilevel shower base of claim 3, wherein the one or more sensors include one or more of a temperature sensor, a light sensor, and a humidity sensor.
 6. The multilevel shower base of claim 3, wherein the one or more sensors are configured to transmit a signal relating to a measurement to a smart device using a local area network.
 7. The multilevel shower base of claim 1, further comprising: directional steam elements.
 8. The multilevel shower base of claim 1, further comprising: light fixture elements.
 9. The multilevel shower base of claim 1, wherein the super-layer structure base has a top layer comprising one or more of stone, marbles, pebbles, or sand.
 10. A multilevel shower base comprising: an impregnable base, wherein the impregnable base is non-permeable; a flange used at least partially to support a super-layer structure base on top of the impregnable base; and a drain connection positioned on the impregnable base and interfacing with the existing drain plumbing.
 11. The multilevel shower base of claim 10, wherein the super-layer base is permeable and includes a series of openings to enable the penetration of steam or water.
 12. The multilevel shower base of claim 10, additionally comprising: one or more sensors configured to send a signal to effectuate a function of one or both the multilevel shower base and a shower space.
 13. The multilevel shower base of claim 10, further comprising: directional steam elements.
 14. The multilevel shower base of claim 10, further comprising: light fixture elements.
 15. The multilevel shower base of claim 10, wherein the super-layer structure base has a top layer comprising one or more of stone, marbles, pebbles, or sand.
 16. A method for a multilevel shower base, the method comprising: positioning an array of disparate supporting structures on an impregnable base as to enable cutting and subsequent continuous support of a sloped portion of the impregnable base; configuring a flange to at least partially to support a super-layer structure base on top of the impregnable base; and interfacing a drain connection positioned on the impregnable base with an existing drain plumbing of a shower.
 17. The method of claim 16, wherein the super-layer base is permeable and includes a series of openings to enable the penetration of steam or water.
 18. The method of claim 16, additionally comprising: incorporating one or more sensors configured to send a signal to effectuate a function of one or both the multilevel shower base and a shower space.
 19. The method of claim 16, wherein the super-layer structure base has a top layer comprising one or more of stone, marbles, pebbles, or sand. 